Single tile having two piece appearance

ABSTRACT

A method and apparatus which includes the use of an S-Tile mold, combined with a scoring/knifing process for providing a channel, which allows for an S-Tile to be produced which appears to be two separate but cooperating tile sections having a general C-shaped cross section. The longitudinal channel  9  may also be painted, colored, or otherwise darkened in order to accent a “shadow” effect which causes the eye to better perceive separation of the two portions  6  and  7  of the tile  5.

BACKGROUND OF THE INVENTION

[0001] Various methods have been employed for making concrete tiles, such as concrete roof tiles. The particular methods used depend on such things as the shape of the tiles being formed. Typically, wet concrete is dispensed onto a moving pallet (a.k.a. “mold”), following which the pallet is passed under a roller and slipper to form and then shape the tile. A knife assembly chops and shapes the opposite edges of the tile. The wet concrete is cured and then removed from the pallet to provide the completed tile.

[0002] In a particular known method of making concrete roof tiles, a conveyor is used to transport the wet concrete from either a continuous mixer or a batch mixer to a making head assembly disposed above a conveyor containing a succession of moving pallets, arranged end-to-end. The pallets define the general shape of the tiles to be formed. As each pallet passes within the making head assembly, wet concrete is dispensed onto the pallet, with the help of a rotating roller which meters the concrete onto the pallet and compresses the wet concrete to a desired thickness. The pallet is then passed beneath a slipper which engages the wet concrete and has a profile selected to provide the concrete with a desired cross-sectional configuration. A knife assembly chops the continuous ribbon of concrete formed on the end-to-end succession of pallets to define the individual tiles and to shape the edges thereof. The pallets with the wet concrete extruded, compressed, shaped and chopped thereon are then separated and advanced to a racker, where the pallets are loaded onto racks for transport to a curing facility. The curing facility typically comprises an oven in which the tiles are heated at a desired temperature and for a desired period of time to cure the concrete. Following that, each concrete tile is removed from its supporting pallet to thereby provide the completed concrete tiles.

BRIEF SUMMARY OF THE INVENTION

[0003] Generally described, the invention includes the use of an S-Tile mold, combined with a scoring/knifing process, which allows for an S-Tile to be produced which appears to be two separate tile sections having a general C-shaped cross section.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

[0004] Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:

[0005]FIGS. 1-15 are prints of digital photographs of a tile 5 according to the present invention. As may be seen these prints also include additional notes or comments added by hand.

[0006]FIG. 16 is a line drawing of the tile 5 according to the present invention.

[0007]FIG. 17 is a side cross-section of the tile of FIG. 16.

[0008]FIG. 18 is a line pictorial view of a modified slipper design 30, which includes a scoring blade 39, which is configured to form the channel 9 during the forming process. Various alternate blade shapes are also shown.

[0009]FIG. 19 is an illustrative drawing of the channel shown in FIG. 17. Partial cross hatching is shown.

[0010]FIG. 20 is an illustrative drawing of alternate channels 9ALT. Partial cross hatching is shown.

DETAILED DESCRIPTION OF THE INVENTION

[0011] The present inventions now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the invention are shown. Indeed, these inventions may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout.

[0012] General Description

[0013] Generally described, the invention includes the use of an S-Tile mold, combined with a scoring/knifing process, which allows for an S-Tile to appear as two separate tile sections having a general C-shaped cross section.

[0014] More Detailed Discussion

[0015] Reference is first made to FIG. 1, which is a pictorial view of a “modified” S-tile 5, which includes portions 6 and 7, and defines a head end HE and a tail end TE. Also provided is a channel 9. It should be understood that this tile shape is intended for installation as a whole on a roofing structure, simulating two cooperating mission tile shapes.

[0016] Referring now also to FIG. 16, the channel can be {fraction (3/16)} inch wide, and {fraction (5/32)} deep, although other configurations are contemplated without departing from the spirit and scope of the present invention, especially if such other configurations are found more structurally and/or aesthetically effective or desirable. This channel 9 simulates the interface of two separate tiles corresponding to portions 6 and 7. It should be understood that this channel may also be painted, colored, or otherwise darkened in order to accent a “shadow” effect which causes the eye to better perceive separation of the two portions 6 and 7.

[0017] Manufacturing Considerations

[0018] The overall manufacturing process can be as follows. Conventional S-type tiles can be made as needed in a conventional S-tile mold (not shown), with occasionally the modified S-tiles 5 being made. In one example, out of 40,000 tiles being made, the last 10-15% could be modified S-tiles. However, other manufacturing ratios may also be provided without departing from the spirit and scope of the present invention, and may be easily varied as needed to accommodate demand.

[0019] The conventional S-tiles will be manually or automatically de-palleted from the mold as is presently done in the art.

[0020] In order to “switch over” to Simulated Two-Piece Mission type tiles, under one version of the invention, the line is stopped and the slipper configuration is changed. Reference is now made to FIG. 18, which is a pictorial view of a modified slipper design 30, which includes a scoring blade 39, which is configured to form the channel 9 during the forming process. In one configuration the scoring blade is {fraction (5/32)} inches high, {fraction (3/16)} inches wide, and 1.5 inches in length, although other configurations are contemplated without departing from the spirit and scope of the present invention.

[0021] As noted above, under the first embodiment of the invention, in order to use the slipper configuration in FIG. 3, the line has to be stopped and the slippers exchanged. However, an alternative invention includes the concept of configuring the slipper to allow the blade 39 to be moved up and down such that it scores as desired in one position, but presents a flat surface flush with the slipper in a second position. Another alternative configuration includes not modifying the slipper at all but simply lowering a tool into place downstream of the slipper; this could be done while the line is going.

[0022] Curing and Installation

[0023] The tile 5 will be allowed to cure as all other tiles, and can be installed in the same manner as a conventional S-tile. However, should the need arise, the channel could be used as a break line should the installer need a half tile width at the end of a course of tiles.

[0024] Alternatives

[0025] There are many alternative channel configurations which may be used. The rectangular channel may be used as shown in FIGS. 17 and 19, or alternative channel shapes such as shown in FIG. 20 may be used.

[0026] Conclusion

[0027] Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. 

That which is claimed:
 1. A method of providing a tile shape, simulating two tile shapes, from one tile mold, comprising the steps of: providing a first tile shape by use of said tile mold; providing the simulation of two separate second tile shapes by a single tile shape by providing a simulation interface channel at a location between two portions of said first tile.
 2. The method of claim 1, wherein two similar shapes are simulated for said second tile shapes.
 3. The method of claim 1 wherein said first tile shape is an S-tile shape and said second tile shapes are two-Piece Mission tile shapes.
 4. The method of claim 1 wherein said simulation interface channel is darkened to provide a shadow effect.
 5. A method of providing a single tile simulating multiple tile shapes from one tile mold, comprising the steps of: providing a first tile shape by use of said tile mold and a first slipper; and providing a second tile shape by use of said tile mold and a second slipper, said second slipper providing a simulation interface channel. 